Volkswagen New Beetle. Manual - part 1240

Installing 

The rest of the assembly is basically a reverse of the disassembling sequence. 

Tightening torques. See SECONDARY AIR SYSTEM COMPONENTS, REMOVING AND 
INSTALLING . 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP)

  

1998-2004 ENGINE

Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle 

TURBOCHARGER, G-CHARGER 

CHARGE AIR PRESSURE WITH TURBOCHARGER 

Turbocharger system components, removing and installing 

Observe rules for cleanliness. See RULES FOR CLEANLINESS . 

1. Exhaust manifold 

z

With turbocharger  

z

Only replace as assembly  

2. Intake manifold  

3. from charge air cooler  

4. Gasket 

z

Replace  

z

Coating (beading) toward intake manifold  

5. 25 N.m (18 ft lb)  

6. Gasket 

z

Note installation position  

7. Bracket 

z

For heat shield (item -9-)  

8. Washer  

9. Heat shield 

z

Engage in bracket (item -7-)  

10. Turbocharger 

z

Only replace as assembly  

z

Removing: remove right drive shaft at transmission: 

See FRONT AXLE SHAFT . 

NOTE:

z

All hose connections are secured with clips. 

z

Charge air pressure must be leak free.  

z

Replace self-locking nuts.  

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

z

Charge air pressure control, checking. See CHARGE AIR PRESSURE SYSTEM, 
CHECKING .  

11. Pressure unit 

z

For charge air pressure control valve  

z

Integral part of turbocharger; cannot be replaced  

12. From Air Cleaner  

13. Gasket 

z

Replace  

14. Sealing ring 

z

Replace  

15. Oil return pipe 

z

To cylinder block  

16. Banjo bolt 

z

25 N.m (18 ft lb)  

17. 15 N.m (11 ft lb)  

18. 40 N.m (30 ft lb)  

19. Bracket  

20. 25 N.m (18 ft lb)  

21. Gasket 

z

Replace  

22. Front exhaust pipe  

23. Connection  

24. 10 N.m (7 ft lb)  

25. Oil supply pipe  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 1: Exploded View Of Turbocharger System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Charge air cooler components, removing and installing 

1. Charge air cooler  

2. 10 N.m (7 ft lb)  

3. Connecting hose  

4. Connecting pipe 

NOTE:

z

All hose connections are secured by clips. 

z

Charge air pressure must be free of leaks. 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle